Method of making midsole-outsole assemblies for shoes



1952 G. 0. FORD 2, 8 4

METHOD OF MAKING MIDSOLE-OUTSOLE ASSEMBLIES FOR SHOES Filed June 25, 1948 3 Sheets-Sheet l IN VEN TOR. GEORGE C. F 0P0 A TTORNEKS,

Jan. 8, 1952 G. 0. FORD 2,581,524

METHOD OF MAKING MIDSOLE-OUTSOLE ASSEMBLIES FOR SHOES Filed June 25, 1948 3 Sheets-Sheet 2 7 r v 7 )f' .10. 3 a 21 I IN VEN TOR.

050905 0. FORD A T TORNE KS.

Jan. 8, 1952 c, FQRD 2,581,524

METHOD OF MAKING MIDSOLE-OUTSOLE ASSEMBLIES FOR SHOES Filed June 25, 1948 3 Sheets-Sheet 3 INVENTOR. GEORGE 6. FORD MLQM A TTOPNEKS.

Patented Jan. 8, 1952 METHOD OF MAKING MIDSOLE-OUTSOLE ASSEMBLIES FOR SHOES George C. Ford, San Marino, Calif., assignor to Joyce,-Inc., Pasadena, Calif., a corporation of California i Applicationtifune 25, 1948. Serial No. 35,200

1 Claim. (01. 12-146) This invention, relates to the art of making shoes and has particularreference to a new and novel shoe construction and method which is an improvement over the subject matter disclosed and claimed in Patent No. 2,067,963, granted January 19, 1937 on an application of William H. Joyce. In order to more readily understand the improvement, I will advert briefly to the Joyce construction. In that shoe an upperhas the lower edges turned under and secured'to an insole. A cushioning midsole embodying a pad of cushioning material, as for eiiample'felt, is associated with a heel lift, and the two parts are en closed entirely around the exposed edge by an edge covering of relatively thin material which is turned over the upper andlower surfaces, re spectively, of the platform so that a covered midsole is created. This midsole is secured to the upper and insole, and a substantially flat outsole is secured to the bottom surface of the midsole.

Certain modifications of this essential construction have been described and claimed in another Joyce Patent No. 2,351,818, but the characteristic features of the Joyce construction reside in the visible covered midsole incorporating a heel lift for the associated upper, and a sepa- I rate and visibleoutsole. H h Such a construction has proved to be wholly satisfactory and commercially popular.

In adopting the joyce construction to a shoe in which the midsole is covered by crepe rubber and has the appearance of crepe rubber which is desirable for certain styles of footwear, I have found it advantageous to modify the construction in certain respects.

A shoe having the appearance of a thick tapered crepe sole is desirable for a certain market, and in such a shoe it is preferable that the thick sole has the appearance of being a homogeneous single slab of crepe rubber. A sole formed entirely of crepe rubber is relatively heavy, hot on i the feet, becomes deformed after wearing for a while, and tends to wear round on the corners.

A general object of this invention is to provide a shoe having the appearance of a crepe sole construction which eliminates the objections mentioned above.

More particularly an object of the invention is to employ in a shoe, light weight resilient materials for a cushioning midsole, the edges of which are covered by sheet crepe rubber, preferably neoprene crepe, and which edge cover encloses the outsole, the latter also being preferably .of'crepe rubber. The teaching of the Joyce Patent No. 2,067,963 may be followed; with=a differ- 2 ence in the relationship and joining of the midsole edge cover and the outsole. This results in a shoe with a cushioning midsole, substantially flat outsole, and both midsole and outsole combined and edge covered so that the whole has the appearance of a thick tapered rubber crepe sole. While the invention was inspired by the objects pointed out above, and was realized by a technique to be described, the general construction and method may be utilized to manufacture a shoe wherein the edge covering for the midsole and outsole is not roughened like crepe rubber, but may be sheet natural or synthetic rubber. or other suitable composition, having any surface finish desired, the characteristic of the shoe being that the edge cover for the midsole extends down over the edge of the outsole.

The foregoing objects and advantages, and others, will become further apparent from a consideration of the detailed description which follows, and referenceto the drawings.

In thedrawings:

Figure l is a side elevation, with parts in section, of a shoe illustrating the invention.

Figure 2 is a perspective of two parts forming the midsole platform.

Figure 3 is a perspective of the midsole platform and outsole.

Figure 4 is a perspective of the midsole platform, the outsole, and the edge covering.

Figure 5 is a fragmentary vertical section taken on the line 5-5 of Figure 4.

Figure 6 is a view similar to Figure 5 with the edge cover turned down and the outsole and edge cover junction bevelled.

Figure 7 is a perspective of the assembled parts shown in Figure 4 with the edge cover cemented down.

Figure 8 is a perspective illustrating the method of pressing the edges of the outsole and edge cover together.

Figure 9 is an enlarged view, partly in section, of the same operation.

Figure 10 is an exploded cross section of the shoe parts, lasted upper, and sole assembly.

Figure 11 is a flow sheet illustrating successive steps in the method which may be used.

Referring to Figure 11, the steps which may be employed in fabricating the shoe may be briefly outlined as follows:

-A toe pad 20 is grooved as shown at 2|, and is joined by cement to a heel lift 22. The joined parts are oven cured at 23 to dry the cement and then comprise a platform 21%. An outsole 25 which is to be cemented to the bottom of the 3 platform 24, and an edge cover it which is to be wrapped around the platform and outsole with the lower edge of the cover flush with the bottom of the outsole. These parts, after having 7 cement applied, are heated together in an oven' at 27, and while the parts are heated, the outsole is applied at 28, the edge cover is put on at 29, and the upper marginal edges of the cover are turned in at 30 and cemented down as shown at 3 I.

This sole assembly is pre-heated at 32, and while the elements remain heated, the outsole and edge cover are mechanically pressed together At 34, the outsole, platform, and edge cover are pressed together, and any cleanup attended to.

neoprene), and is relatively thin, the toe pad being relatively thick.

The edge cover 26, as illustrated, is also made of sheet crepe rubber (preferably neoprene), and

may be thinner than the outsole. It isfashioned 7 so that it will entirely encircle .the platform (see Figure 4) and ispreferably overlapped as shown at 52, the lower edge covers and is flush with the bottom edge of the outsole (see Figure 5), and there is marginal material 53 to turn in and cement down to the upper surface of the platform, as illustrated in Figure 7.

The shoe couldbe made, although I believe less efficiently, ,by first attaching the edge cover to the upper and insole to form a pocket, and then inserting the platform, and attaching the out-- sole, but themethod first described is considered The lasted upper and insole assembly 35 is oven cured with the sole assembly at 35, and the two major elements, having cement on the contiguous surfaces, pressed together at 31 to complete the shoe 3B.

This is but a sketch of the manufacturing steps, and is illustrative only, being subject to many variations.

Referring now to'Figures 1 etseq., the shoe 38 comprises essentially an upper 39 secured to 'an insole 40 over which is optionally secured a .sock lining and a sole unit W2 which comprises the superior.

The groove 2| accommodates the thickness of the edge cover, and while not absolutelynecessary, imparts a desirablefeature of comfort to the shoe. 7

It is desirable to .bevel the joined edge of the outsole and cover as shown at54 by 'anabrasive machine or other means.

An important contribution 'to the art of shoe making lies in the method of bonding the butt 7 joint between'the edge cover and outsole.

platform 24, outsole 25 and edge cover '26, the

upper edges of which are turned in over the upper surface of the platform, and the lower edge of which covers and is flush with the bottom of the outsole.

In the illustration, theupper is constructed ac-..

cording to known art, particularly the Joyce Pat- 'ent No. 2,O6'7,963,'with thelower edges of the upper turned under and secured to the lower marginal surface "of the insole 40.

' In the illustration, also, the sole unit '42 is made separately, and in the relationship shown in Figure 10, the major parts are cemented together.

The toe 'pad'zfl 'is'prefera'bly made of cushion cork composition, and is bevelled and cut as It .is'

shown, to join neatly with the heel lift'22. 'of generally uniform thickness, but is'provided 'with the groove 21 'inthe upper surface to receive the turned in part of the edge covering. This is desirable, although not essential, to as- 7 sure a smoother toe surface under'the insole.

The 'heel lift22 is desirably made of a'harder material than the toe'pad, asfor example'a'composition ofcork, sawdust, synthetic'resin, and latex, and is cut and'tapered as shown complementary to the toe pad so that when the'two'parts are joined, the platform-thus'made'is substantially smooth on both upper and lower surfaces, the bottom is fiat, andthe top rises with an arch effect.

As an equivalent, thetoe pad and heel'lift may be formed in one piece of any suitable material, so long as'the toe portionis flexihle and offers some resiliency. It is not essential that theheel lift be of a cushioning material. 'Or'the relative sizes and shapes of thetoepad andheel' lift may;

be mutually altered, and the toepad-extended up over the heel lift, as illustrated in the Joyce Patent No. 2,067,963, or'itmay extend backunder the heel lift; or the platform may be laminated.

The greatest benefits are obtained, however, if,

the material is lighter than solid crepe rubber, if the toe portion is flexible, and somecushioning effect is obtained over the entire platform.

The outsole 25 exactly coincides in outline with the shape of theplatform. In theillustraev tion it is made of sheet crepe rubber (preferably the outsole "and the contacting surface of the cover, and the twosurfaces initially pressed together.

The firststep is to heat the assembled parts,-as at station 32, Figure 1"1, which can be conveniently done in an oven. Wi-th neoprene crepe rubber as the material used-Thave-found in practice that a heating from to 'F'. for about 7 to '8minutes is adequate.

The second-step i-s,-immediately out of the oven and whilethe materials are hotythe corner edges are rolled as at station 33.

The essential parts-of a machine suitable for practicing my-method comprise heated-rollers 55 and 56 (Figure 9) which areheatedby-means not shownand maintained at aternperature ranging 'from--100 F.'t0 12-5' F. They are-power'driven by meansnot shown, turning-at 24 R. 'P. M. to36 R. P. M. The rollers are spacedaparta distance less than'the combined thickness of the outsole and edge cover, and-preferably are groove'dor knurled as illustrated at 51. r

The preferred operation is-to feed the sole unit edge between the rollers, all around'the sole unit.

Ifproperlydone one. revolution is sufficient. The

sole=unit isheld'sothat the bottom of the outsole is at an angle of about 30to the plane ofthe ends :of the rollersand about of the joined crepe. is fed between the rollers.

This rollingpressure under :heat results in a bond which is as strong, or stronger, than the crepe itself. .The material is l.00% ,returnable to original form, and when releasedfromthe rollers, thebutt joint is neatand permanent, the sides of the sole unit are straight, and .unmarred, and

the outsole is'flat.

The sole unit thus fabricated i light weight,

flexible and soft, and attractive, having the appearance of a homogeneous unit, and imparting overall height, and cushioning to the shoe.

Various modifications in the details of fabrie cation, and the shoe construction, will be apparent to anyone skilled in the art. Instead of neoprene crepe, any other suitable material may be employed for the outsole and edge cover, so long as they are amenable to the treatment prescribed, and possess, either inherently or in conjunction with an adhesive or solvent, the ability to bond together in a butt joint of the character shown and described, and are not permanently deformed or marred beyond repair in the physical treatment which may be employed to aid in the bonding. 'It is also apparent, of course, that the material oi the edge cover be durable enough to withstand wear on the exposed lower edge.

The heel lift may be omitted, if desired, and

the cushioning pad of substantially constant thickness extend the full length of the shoe.

While I have herein shown and described my invention in what I have conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope of my invention, which is not to be limited to the details disclosed herein, but is to be accorded the full scope of the claim so as to embrace any and all equivalent shoe construction and method of manufacture.

Having described my invention, what I claim as new and desire to secure by Letters Patent is:

In the art of making edge covered outsoles and midsoles assemblies, the novel step of providing a midsole, an outsole of rough surfaced crepe rubber material and a cover for the outsole and midsole of rough crepe rubber material, said crepe rubber material being amenable to cement and pressure bonding, applying cement to said cover and to the portions of the midsole and outsole to be covered, pressing said cover onto said soles with the lower edge of the cover flush with the bottom of the outsole, heating said joined cover and outsole, deforming the material at the juncture of cover and outsole by stretching and pinching together the material all around the outsole to establish substantially full area contact and adhesion between the edge of said outsole and the contiguous surface of said cover, and releasing the stretched and pinched material permitting the same to return to substantially normal shape.

GEORGE C. FORD.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,583,096 Pierce et al. May 4, 1926 2,046,444 Belyea July 7, 1936 2,071,725 Bickford Feb. 23, 1937 2,074,579 Fesl Mar. .23, 1937 2,230,504 Rudner Feb, 4, 1941 2,276,686 Chevalier Mar. 117, 1942 2,303,022 Calderazzo Nov. 24, 1942 2,367,808 Starner Jan. 23, 1945 2,379,681 Cohen July 3, 1945 2,381,503 Le Rette Aug. 7, 1945 

